Methods for producing viloxazine salts and novel polymorphs thereof

ABSTRACT

Provided here are methods of manufacture of viloxazine and its various salts, as well as viloxazine-related compounds, such as novel intermediate reaction products and polymorphs thereof. In particular, the methods provide a substantially pure API of viloxazine HCl while avoiding undesirable impurities. The methods further provide for separating, identifying, and characterizing novel polymorphs of viloxazine. Further provided are methods for synthesis and identification and characterization of novel intermediates of viloxazine, as well as for some important metabolites and precursors of metabolites of viloxazine.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a Continuation Application of U.S. patentapplication Ser. No. 15/988,190, filed May 24, 2018, which is aContinuation Application of U.S. patent application Ser. No. 15/192,098,filed Jun. 24, 2016, now U.S. Pat. No. 10,005,743, which is aContinuation Application of U.S. patent application Ser. No. 13/084,612,filed Apr. 12, 2011, now U.S. Pat. No. 9,403,783, which claims priorityto U.S. Provisional Application No. 61/323,151, filed on Apr. 12, 2010,the contents of these applications are incorporated by reference intheir entirety.

FIELD

Described herein are methods for improved production of activepharmaceutical ingredients (“APIs”) such as viloxazine, includingmethods having increased yields and producing decreased amounts ofimpurities. This disclosure further describes and characterizes salts ofAPIs such as viloxazine hydrochloride, including novel polymorphsthereof.

BACKGROUND

Viloxazine ((R,S)-2-[(2-ethoxyphenoxy)methyl]morpholine]) is a bicyclicmorpholine derivative, assigned CAS No. 46817-91-8 (CAS No. 35604-67-2for the HCl salt). It is characterized by the formula C₁₃H₁₉NO₃, with amolecular mass of 237.295 g/mol. Viloxazine has two stereoisomers,(S)-(−)- and (R)-(+)-isomer, which have the following chemicalstructures:

Viloxazine is known to have several desirable pharmacologic uses,including treatment of depression, nocturnal enuresis, narcolepsy, sleepdisorders, and alcoholism, among others. In vivo, viloxazine acts as aselective norepinephrine reuptake inhibitor (“NRI”). Between the twostereoisomers, the (S)-(−)-isomer is known to be five times aspharmacologically active as the (R)-(+)-isomer. See, e.g., “OpticalIsomers of 2-(2-ethoxyphenoxymethyl)tetrahydro-1,4 oxazine (viloxazine)and Related Compounds” (Journal of Medicinal Chemistry, Jan. 9, 1976,19(8); 1074) in which it is disclosed that optical isomers of2-(2-ethoxyphenoxymethyl)tetrahydro-1,4-oxazine (viloxazine) and2-(3-methoxyphenoxymethyl)tetrahydro-1,4-oxazine were prepared andabsolute configurations assigned. The synthesis of optical isomers ofviloxazine analogs of known configuration was accomplished by resolutionof the intermediate4-benzyl-2-(p-toluenesulfonyloxymethyl)tetrahydro-1,4-oxazine isomers.

Some unsatisfactory methods of synthesizing viloxazine are known in theart. For example, as disclosed in U.S. Pat. No. 3,714,161, viloxazine isprepared by reacting ethoxyphenol with epichlorohydrin to afford theepoxide intermediate 1-(2-ethoxyphenoxy)-2,3-epoxypropane. This epoxideintermediate is then treated with benzylamine followed with chloroacetylchloride. The resulting morpholinone is then reduced by lithium aluminumhydride and then by Pd/C-catalyzed hydrogenation to yield viloxazinefree base.

Yet another unsatisfactory synthesis of viloxazine is disclosed in U.S.Pat. No. 3,712,890, which describes a process to prepare viloxazine HCl,wherein the epoxide intermediate, 1-(2-ethoxyphenoxy)-2,3-epoxypropane,is reacted with 2-aminoethyl hydrogen sulfate in ethanol in the presenceof sodium hydroxide to form viloxazine free base. The product isextracted with diethyl ether from the aqueous solution obtained byevaporating the solvent in the reaction mixture then adding water to theresidue. The ethereal extract is dried over a drying agent and thesolvent is removed. Viloxazine HCl salt is finally obtained bydissolving the previous residue in isopropanol, concentrated aqueousHCl, and ethyl acetate followed by filtration.

The foregoing methods of synthesizing viloxazine suffer from a number ofdeficiencies, such as low reaction yield and unacceptably large amountof impurities in the resulting product. Effective elimination or removalof impurities, especially those impurities possessing genotoxicity orother toxicities, is critical to render safe pharmaceutical products.For example, certain reagents traditionally utilized in viloxazine HClpreparation, such as epichlorohydrin and 2-aminoethyl hydrogen sulfate,present a special problem due to their toxicity. There is a need foreffective methods to remove or limit harmful impurities down to a levelthat is appropriate and safe according to contemporary sound medicalstandards and judgment. Accordingly, a continuing and unmet need existsfor new and improved methods of manufacturing viloxazine and its varioussalts to yield adequate quantities of pharmacologically desirable APIwith predictable and reliable control of impurities.

Polymorph control is also an important aspect of producing APIs andtheir associated salts that are used in pharmaceutical products.However, no polymorphs of viloxazine HCl have previously been disclosed.A need therefore exists for new polymorphic forms of viloxazine thathave improved pharmacological properties.

SUMMARY OF THE INVENTION

Provided herein are new and improved methods of manufacture ofviloxazine and its various salts, as well as viloxazine-relatedcompounds, such as novel intermediate reaction products. In particular,the methods herein provide a substantially pure API of viloxazine HClwhile avoiding undesirable impurities. The methods further provide forsynthesizing, separating, identifying, and characterizing novelpolymorphs of viloxazine. Further provided are methods for synthesis andidentification and characterization of novel intermediates ofviloxazine, as well as for some important metabolites and precursors ofmetabolites of viloxazine.

In an exemplary embodiment, the invention provides a substantially purecomposition suitable for use as an active pharmaceutical ingredient, thecomposition consisting essentially of viloxazine or a pharmaceuticallyacceptable salt thereof and comprising less than about 1.5 μg of anygenotoxic impurity per expected human daily dosage. In another exemplaryembodiment, the composition comprises less than 0.5 μg of any genotoxicimpurity per expected human daily dosage.

In a further embodiment, the invention provides a method ofmanufacturing viloxazine through a 3-step process, wherein in the firststep 2-ethoxyphenol and epichlorhydrin are reacted to produce1-(2-ethoxyphenoxy)-2,3-epoxypropane (Epoxide 1); in the second step,1-(2-ethoxyphenoxy)-2,3-epoxypropane (Epoxide 1) is converted intoviloxazine base which is further converted into viloxazine salt, and inthe third Step viloxazine salt is purified/recrystallized, and variouspolymorphic forms of viloxazine salt are prepared.

In a further embodiment, the invention provides a method ofmanufacturing a 2-substituted morpholine, such as viloxazine, comprising(1) providing a diol compound according to the following formula:

wherein R^(b) is a hydrogen or a nitrogen-protecting group, and R^(c) isa substituted or unsubstituted aryloxy group, a substituted orunsubstituted alkyl group, or a substituted or unsubstituted alkoxygroup; (2) reacting the diol compound with a base and a cyclizationagent to yield a 2-substituted morpholine having the following formula:

In a variation of step (2) in the embodiment, a single phasic, or aliquid-liquid or solid-liquid biphasic system can be employed. In afurther variation of step (2) in the embodiment, a phase transfercatalyst can be employed. In yet another further variation of theembodiment, the diol is treated with a base first, followed bycyclization agent.

In yet another embodiment, the invention provides a compound accordingto the following formula:

wherein R^(a) is a substituted or unsubstituted aryloxy group or asubstituted or unsubstituted alkoxy group, and R^(b) is hydrogen or anitrogen-protecting group.

In yet another embodiment, the invention provides a method ofmanufacturing viloxazine by reacting1-(2-ethoxyphenoxy)-2,3-epoxypropane with 2-aminoethyl hydrogen sulfatein a solution with a very large excess of a base. In a further variationof the embodiment, the base is added to the reaction mixture in astepwise manner.

In yet another embodiment, the invention provides a compositioncomprising viloxazine hydrochloride polymorph Form A, the polymorphhaving a powder X-ray diffraction spectrum and a Raman infrared spectrumas illustrated in FIG. 6 and FIG. 9.

In a different embodiment, the invention provides a compositioncomprising viloxazine hydrochloride polymorph Form B, the polymorphhaving a powder X-ray diffraction spectrum and a Raman infrared spectrumas illustrated in FIG. 7 and FIG. 10.

In yet another embodiment, the invention provides a pharmaceuticalcomposition comprising viloxazine hydrochloride polymorph Form A,polymorph Form B, or a combination thereof.

Additional features may be understood by referring to the accompanyingdrawings, which should be read in conjunction with the followingdetailed description and examples.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1, schematically illustrates the preparation of1-(2-ethoxyphenoxy)-2,3-epoxypropane (“Epoxide 1”) in accordance withthe first step (“Step I”) of an exemplary synthesis of viloxazine:

FIG. 2, schematically illustrates the preparation of1-(2-ethoxyphenoxy)-2,3-epoxypropane (“Epoxide 1”) in accordance withthe first step (“Step I”) of another exemplary synthesis of viloxazine(biphasic):

FIG. 3, schematically illustrates the preparation of viloxazine (“StepIIa”) and the preparation of viloxazine hydrochloride (“Step IIb”), aswell as their purification (“Step III”) in accordance with anotherexample embodiment hereof.

FIG. 4, schematically illustrates the preparation of viloxazine and itssalts via “Diol 1” in accordance with another exemplary embodimenthereof (Bn=benzyl, Et=ethyl).

FIG. 5, schematically illustrates the cyclization of Diol 1, as well assome side-reactions thereof.

FIG. 6 shows an XRPD pattern of Viloxazine HCl, Form A.

FIG. 7 shows an XRPD pattern of Viloxazine HCl, Form B.

FIG. 8 shows an XRPD pattern of recrystallized Viloxazine HCl, Form A.

FIG. 9 shows a Raman spectrum of viloxazine HCl, Form A.

FIG. 10 shows a Raman spectrum of viloxazine HCl, Form B.

DETAILED DESCRIPTION

Provided herein are new and improved methods of manufacture ofsubstantially pure compositions of viloxazine and pharmaceuticallyacceptable salts and polymorphs thereof with improved control ofimpurities to thereby provide materials suitable for pharmaceuticalapplications.

For the sake of convenience and without putting any limitations thereof,the methods of manufacture of viloxazine have been separated intoseveral steps, each step being disclosed herein in a multiplicity ofnon-limiting embodiments. These steps comprise Step 1, during which2-ethoxyphenol and epichlorhydrin are reacted to produce1-(2-ethoxyphenoxy)-2,3-epoxypropane (Epoxide 1); Step 2, during which1-(2-ethoxyphenoxy)-2,3-epoxypropane (Epoxide 1) is converted intoviloxazine base which is further converted into viloxazine salt, andStep 3, during which viloxazine salt is purified/recrystallized, andvarious polymorphic forms of viloxazine salt are prepared.

The above-mentioned steps will be considered below in more details.

The process of the Step 1 may be advantageously carried out in thepresence of a phase-transfer catalyst to afford near quantitative yieldof 1-(2-ethoxyphenoxy)-2,3-epoxypropane. Alternatively, the process maymake use of a Finkelstein catalyst described in more details below.Additionally, the reaction may take place without the use of thecatalyst.

FIG. 1, depicted below, schematically illustrates the preparation of1-(2-ethoxyphenoxy)-2,3-epoxypropane (“Epoxide 1”) in accordance withStep I of an exemplary synthesis of viloxazine:

Step I

In one embodiment of the Step 1, the preparation of1-(2-ethoxyphenoxy)-2,3-epoxypropane (epoxide 1) can be effected by theuse of a phase transfer catalyst in the presence of a solid or liquidbase with a solution of a corresponding phenol and epichlorohydrin inone or more solvents (FIG. 1). The phase transfer catalyst can beselected from ammonium salts, such as benzyltriethylammonium salts,benzyltrimethylammonium salts, and tetrabutylammonium salts, phosphoniumsalts, guanidinium salts, crown ether, polyethylene glycol, polyethyleneglycol ether, or polyethylene glycol ester, or other phase transfercatalysts know in the art. The solid or liquid base can be a carbonatesuch as alkali carbonate, NaOH, KOH, LiOH, LiOH/LiCl, amines such asmono-, di- or tri-substituted amines (such as diethylamine,triethylamine, dibutylamine, tributylamine), DMAP, or other appropriatebase. The solvents used in the solution of a corresponding phenol andepichlorohydrin include but are not limited to ethers such as methylt-butyl ether, ketones, non-substituted or substituted aromatic solvents(xylene), halo-substituted hydrocarbons (e.g. CH2Cl2, CHCl3), THF, DMF,dioxanes, non-substituted and substituted pyridines, acetonitrile,pyrrolidones, nitromethane, or other appropriate solvent. Additionalcatalyst, such as, for example, Finkelstein catalyst, can also be usedin the process of this embodiment. This reaction preferably takes placeat an elevated temperature. In one variation of the embodiment, thetemperature is above 50° C. In another variation, epichlorohydrin,potassium carbonate, and a phase transfer catalyst are mixed with asolution of 2-ethoxyphenol in a solvent at an elevated temperature, suchas 50-60° C. After the reaction is complete, the reaction mixture can bewashed with water, followed by work-up procedures known in the art.Variations of this embodiment of the invention are further disclosed inExamples 1-8.

In one variation of the above embodiment of the Step 1, Epoxide 1 isprepared by reacting 2-ethoxyphenol and epichlorohydrin in a solvent inthe presence of two different catalysts, and a base in a solid state.The first catalyst is a phase transfer catalyst as described above; thesecond catalyst is a Finkelstein reaction catalyst. Without putting anylimitation hereon, metal iodide and metal bromide salts, such aspotassium iodide, may be used as an example of a Finkelstein catalyst.The phase transfer catalyst and a solvent may be selected from any phasetransfer catalysts and solvents known in the art. Potassium carbonatemay be used as a non-limiting example of a solid base. Using the solidbase in a powdered form may be highly beneficial due to the greatlyenhanced interface and limiting the side reactions. This variation ofthe embodiment is further illustrated by Example 9. In another variationof the embodiment, liquid base such as triethylamine can be used toreplace the solid base.

In a different embodiment of Step 1, 2-ethoxyphenol and epichlorohydrinare reacted in a solvent-free system that comprises a solid or liquidbase, a phase transfer catalyst as listed above and a Finkelsteincatalyst.

FIG. 2, depicted below, schematically illustrates the preparation of1-(2-ethoxyphenoxy)-2,3-epoxypropane (“Epoxide 1”) in accordance withthe Step I of another exemplary synthesis of viloxazine (biphasic):

Step I (Alternative Embodiment)

In this embodiment of Step 1, illustrated in FIG. 2, Epoxide 1 can beprepared by reacting epichlorohydrin with 2-ethoxyphenol in the presenceof a catalytic amount of a phase transfer catalyst without the use ofsolvents at elevated temperatures in a two-stage process to afford nearquantitative yield of 1-(2-ethoxyphenoxy)-2,3-epoxypropane with very fewside products. This embodiment of the invention is further illustratedby a non-limiting Example 12. The phase transfer catalyst for thisembodiment can be selected from ammonium salts such asbenzyltriethylammonium salts, benzyltrimethylammonium salts,tetrabutylammonium salts, etc; phosphonium salts, guanidinium salts,crown ether, polyethylene glycol, polyethylene glycol ether, orpolyethylene glycol ester, or other phase transfer catalysts know in theart. The first stage of the process of this embodiment may take placewithout a solvent in a presence of a large excess of epichlorohydrin.This stage is followed by a de-chlorination stage, before or afterremoval of excess epichlorohydrin, using a base and a solvent. Thereaction produces 1-(2-ethoxyphenoxy)-2,3-epoxypropane in high yield.Example of the bases used herein include but are not limited to NaOH,KOH, LiOH, LiOH/LiCl, K2CO3, Na2CO3, amines such as mono-, di- ortri-substituted amines (such as diethylamine, triethylamine,dibutylamine, tributylamine etc.), DMAP. In one variation of thisembodiment of Step 1, the phase transfer catalyst may be used only atthe de-chlorination stage of the process. The de-chlorination stage canbe carried out in a biphasic system or in a single phase system. For abiphasic system, it can be an organic-aqueous liquid biphasic system, ora liquid-solid biphasic system. Solvents that are useful for the processinclude but are not limited to non-substituted and substituted aromaticsolvents (e.g. toluene, benzene, chlorobenzene, dimethylbenzene,xylene), halo-substituted hydrocarbons (e.g. CH2Cl2, CHCl3), THF,dioxanes, DMF, DMSO, non-substituted and substituted pyridines, ketones,pyrrolidones, ethers, acetonitrile, nitromethane. As mentioned above,this process takes place at the elevated temperature. In one variationof the embodiment, the temperature is above 60° C. In another variation,2-ethoxyphenol and epichlorohydrin are heated to 60-90° C. for a periodof time in the presence of phase transfer catalyst. Excess ofepichlorohydrin is removed and the residue is dissolved in a solventsuch as toluene or benzene treated with an aqueous base solution, suchas NaOH, KOH, LiOH, LiOH/LiCl. In yet another variation of theembodiment, the residue after epichlorohydrin removal can be dissolvedin one or more of the said solvent and treated with a base (solid orliquid but not an aqueous solution) and optionally a second phasetransfer catalyst, optionally at elevated temperatures.

In yet another embodiment of Step 1, Epoxide 1 can also be prepared byusing a catalyst for a so-called Finkelstein reaction in the presence ofa Finkelstein catalyst but without the need to use a phase transfercatalyst. Finkelstein catalysts useful herein include metal iodide saltsand metal bromide salts, among others. In one variation of thisembodiment, 2-ethoxyphenol and epichlorohydrin are dissolved in a polaraprotic solvent such as DMF, and a catalytic amount of an iodide such aspotassium iodide and a base, as solid or liquid, are used. Preferably,the base is used as a solid, such as potassium carbonate powder. Thisembodiment is further illustrated by the Example 11.

In the alternative embodiment of Step 1, Epoxide 1 can also be preparedby a different method that comprises reacting epichlorohydrin and thecorresponding phenol in the presence of a base at a temperature lowerthan the ambient temperature, especially when a base solution is used,and without the use of a phase transfer catalyst. This embodiment isillustrated by the Example 10.

A very high, almost quantitative, yield of1-(2-ethoxyphenoxy)-2,3-epoxypropane can be obtained through realizingthe above-described embodiments of Step 1, with less impuritiesgenerated in Epoxide 1.

Epoxide 1, produced in Step 1 as described above, is used to prepareviloxazine base (viloxazine), which is further converted into viloxazinesalt through the processes of Step 2.

FIG. 3, depicted below, schematically illustrates the preparation ofviloxazine (“Step IIa”) and the preparation of viloxazine hydrochloride(“Step IIb”), as well as their purification (“Step III”) in accordancewith another example embodiment hereof:

Step IIa

Step IIb

Step III

In the embodiment of Step 2, illustrated in FIG. 3, the preparation ofviloxazine base is achieved by reacting the Epoxide 1 intermediateprepared in Step 1 and aminoethyl hydrogen sulfate in presence of alarge excess of a base as illustrated by the Examples 5-7 and 14. Thebase may be present as a solid or in a solution. Preferably, the molarratio of the base to Epoxide 1 is more than 10. More preferably theratio is more than 12. Even more preferably, the ratio is between 15 and40. It was unexpectedly discovered that the use of a higher ratio of abase results in a faster reaction, less impurities, and lower reactiontemperature.

Further advantages may be offered by a specific variation of thisembodiment, wherein the base is added to the reaction mixture in severalseparate steps. For example, a third of the base is added to thereaction mixture, and the mixture is stirred for a period of time. Thenthe rest of the base is added followed by additional stirring.Alternatively, half of the base is added initially followed by thesecond half after some period of time, or the base is added in threedifferent parts separated by periods of time. The bases used hereininclude but are not limited to NaOH, KOH, LiOH, LiOH/LiCl, K2CO3,Na2CO3, amines such as mono-, di- or tri-substituted amines (such asdiethylamine, triethylamine, dibutylamine, tributylamine), DMAP, andcombinations thereof. In one embodiment of the invention, the base isKOH. In another embodiment, the base is NaOH. In a further embodiment,the base is K2CO3 powder. In yet further embodiment, the base istriethylamine. This embodiment is illustrated further by Examples 13, 15and 16.

In another exemplary embodiment of Step 2, viloxazine is produced bycyclization of novel intermediate compound “Diol 1,” which is made fromEpoxide 1 and N-benzyl-aminoethanol. This method allows one todrastically reduce the use of potentially toxic materials in themanufacturing process, completely eliminating some of them such asaminoethyl hydrogen sulfate. The first stage of the reaction results inthe formation of an intermediate of Formula 3 (Diol 1), which is a new,previously unidentified compound.

FIG. 4, depicted below, schematically illustrates the preparation ofviloxazine and its salts via “Diol 1” in accordance with anotherexemplary embodiment hereof (Bn=benzyl, Et=ethyl):

As illustrated in FIG. 4, Diol 1 is turned into N-benzyl viloxazine bycyclization. Removal of the benzyl protective group yields viloxazinebase. Similarly, FIG. 5, depicted below, schematically illustrates thecyclization of Diol 1, as well as some side-reactions thereof.

In one variation of the embodiment, epoxide 1 and N-benzyl aminoethanolcan be refluxed in a solvent to form Diol 1 in quantitative yield. Thesolvent is selected from those having a boiling point of 50° C. or more.Preferably, the boiling point is 60° C. or more. More preferably, theboiling point is 70° C. or more. For example, Diol 1 can be prepared inquantitative yield by refluxing toluene with 2-4 volume/g of the epoxide1 and about 1 equivalent of N-benzyl aminoethanol, which can be addedslowly to the solution at about 110° C. (see Example 17).

Any of several methods can be used to efficiently perform thecyclization reaction of Diol 1. In one example, Diol 1 can be turnedinto N-benzyl viloxazine via cyclization reaction effected by an acid,such as sulfuric acid or hydrochloric acid.

In another variation of the embodiment, cyclization can be achievedthrough the use of a cyclization agent. Examples of the cyclizationagents include but are not limited to sulfonyl halides such as tosylchloride, brosyl chloride, nosyl chloride and mesyl chloride, DMSO,alumina. Other methods for cyclization of diols known in the art canalso be used. The cyclization can be carried out in a biphasic system ora single phase system.

Further, it was unexpectedly discovered that a phase transfer catalystcan also be advantageously utilized in the cyclization. The phasetransfer catalyst used herein can be selected from ammonium salts,phosphonium salts, guanidinium salts, crown ether, polyethylene glycol,polyethylene glycol ether, or polyethylene glycol ester, or other phasetransfer catalysts known in the art.

Bases can be used to facilitate the cyclization reaction, especiallywhen the cyclization agent is a sulfonyl chloride. The bases that areuseful in the said process include but are not limited to NaOH, KOH,LiOH, LiOH/LiCl, K2CO3, Na2CO3, nitrogen-containing bases such as mono-,di- or tri-substituted amines (such as diethylamine, triethylamine,dibutylamine, tributylamine), dimethylaminopyridine (DMAP),N,N-diisopropylethylamine (DIPEA), 1,4-diazabicyclo[2.2.2]octane(DABCO), 1,8-diazabicyclo[5.4.0]undec-7-ene (DBU), piperidine andderivatives, pyrrolidine and derivatives, quinine, imidazole, alkalisalts of carbanions, amides, and hydrides.

Solvents can also be used to facilitate the cyclization reaction.Examples of the solvents used herein include, but are not limited to,non-substituted and substituted aromatic solvents (e.g. toluene,benzene, chlorobenzene, dimethylbenzene, xylene), halo-substitutedhydrocarbons (e.g. CH2Cl2, CHCl3), THF, dioxanes, tetrahydrofuran (THF),N,N-dimethylformamide (DMF), dimethyl sulfoxide (DMSO), non-substitutedand substituted pyridines, ketones, pyrrolidones, ethers, acetonitrile,nitromethane. Water can also be used, especially in a biphasic system.In one variation of this embodiment, cyclization can be carried out inthe presence of a phase transfer catalyst in a biphasic system whereinDiol 1 is dissolved in the organic phase and the base is dissolved inthe aqueous phase. For example, Diol 1 is treated with toluenesulfonylchloride in the presence of phase transfer catalystbenzyltriethylammonium chloride in a biphasic system wherein an aqueoussolution of NaOH is used together with an organic solvent such astoluene. In a separate variation of this embodiment, a solid base may besuccessfully used in this step instead of an aqueous base in asolid-liquid biphasic system.

In a further embodiment, the invention provides a method ofmanufacturing a 2-substituted morpholine, such as viloxazine, comprising(1) providing a diol compound according to the following formula:

wherein R^(b) is a hydrogen or a nitrogen-protecting group, and R^(c) isa substituted or unsubstituted aryloxy group, a substituted orunsubstituted alkyl group, or a substituted or unsubstituted alkoxygroup; (2) reacting the diol compound with a base and a cyclizationagent to yield a 2-substituted morpholine having the following formula:

In a variation of step 2 of the embodiment, a single-phasic, or aliquid-liquid or solid-liquid biphasic system can be employed. In afurther variation of step 2 in the embodiment, a phase transfer catalystcan be employed. In yet another further variation of the embodiment, thediol is treated with a base first, followed by a cyclization agent.

The addition sequence and the ratio of the reagents for the cyclizationreaction can be controlled to obtain maximum yield, improve the purityof the product or to control the side reactions that lead to theformation of two minor, but previously uncharacterized, impurities ofFormula 4 and Formula 5:

For example, the cyclization agent may be added to the mix after thebase is introduced. The Diol 1 concentration may be controlled toprevent the formation of the by-products.

This embodiment of step 2 and its variations are further illustrated inExample 17.

Still referring to FIG. 4, viloxazine can be prepared from N-benzylviloxazine by removing the benzyl protection group. Many methods can beused to remove the benzyl group herein. Reductive deprotection is one ofthe methods that can be utilized. Catalytic hydrogenation for removingthe benzyl group can be carried out by using Pd/C, Pd(OH)₂/C, Pd/CPS(CPS carbon powder support type 1, 2, 3 or 4), and other suitablecatalysts know in the art. Hydrogen source can be from H2, or in situgenerated hydrogen source such as formamide. Other reagents that canfacilitate catalytic debenzylation can also be used. Such facilitatingagents can be an agent that reduces catalyst poisoning, such as an acid(see, for example, Example 18).

Known processes for synthesis of viloxazine produce impurities, whichcan have undesirable pharmacological properties. In particular, knownprocesses provide the following undesirable impurities or by-products:(1) Epichlorohydrin and/or 1-(2-ethoxyphenoxy)-2,3-epoxypropane; (2)2-aminoethyl hydrogen sulfate; and (3) aminoethyl sulfate ester of analcohol. These undesirable by-products can be eliminated, or theiramounts can be drastically reduced, by the improved methods of synthesisof viloxazine as described above. The removal of the remainingimpurities, especially those having higher toxicity potential, can beaccomplished by the improved techniques for the isolation andpurification of the reaction products. These techniques include freebase-salt interconversion that may be performed in multiple cycles;extraction step during work-up and/or during base-salt interconversion;additional crystallization, precipitation, washing, or drying stepperformed during one or more cycles of free base-salt conversion; one ormore cycles of recrystallization, or combinations of the abovetechniques.

In a further reference to Step 2, some embodiments of the current methodas described above avoid the use of toxic compounds like 2-aminoethylhydrogen sulfate, thus completely eliminating their presence in thefinal product.

Referring to the embodiments of Step 2, after viloxazine free base isformed, it can be extracted into a solvent such as methyl tert-butylether, and then converted to HCl salt by using an aqueous HCl solution.The crude viloxazine HCl can be purified by 1. conversion to viloxazinefree base by using a base solution; 2. extraction by a solvent such asmethyl tert-butyl ether, 3. optionally washing or drying or filteringthe extraction solution, and 4. converting the free base to the salt byusing an aqueous HCl solution. This cycle may be repeated as necessaryuntil the desired purity is achieved. Once the conversion cycle iscomplete, the free base can be turned into the HCl salt by using HCl anda solvent system suitable for preparing a particular polymorph ofviloxazine HCl. Alternatively, the viloxazine HCl salt can undergo oneor more cycles of recrystallization using a suitable solvent system toproduce a desired polymorph of viloxazine HCl. Analytical methodscapable of detecting extremely low threshold levels set for genotoxiccompounds by today's standards show that viloxazine HCl product thusproduced has virtually no trace of the epichlorohydrin,1-(2-ethoxyphenoxy)-2,3-epoxypropane, and 2-aminoethyl hydrogen sulfate(even if this reagent was used in the reaction).

In one embodiment, the methods provide viloxazine and its HCl salt withamounts of less than about 2.5 ppm of impurities selected from the groupconsisting of epichlorohydrin, 1-(2-ethoxyphenoxy)-2,3-epoxypropane, and2-aminoethyl hydrogen sulfate. It is important to note that no alcoholesters of aminoethyl sulfate, which are potentially toxic materials, areformed through the processes of the current invention.

In another embodiment, the methods provide viloxazine and its HCl saltwith detectable amounts of less than about 1 ppm of impurities selectedfrom the group consisting of epichlorohydrin,1-(2-ethoxyphenoxy)-2,3-epoxypropane, and 2-aminoethyl hydrogen sulfate.

In a further embodiment, the methods herein provide viloxazine and itsHCl salt with no detectable amounts of impurities selected from thegroup consisting of epichlorohydrin,1-(2-ethoxyphenoxy)-2,3-epoxypropane, and 2-aminoethyl hydrogen sulfate(see Example 22).

In a further embodiment, the methods herein provide viloxazine and itsHCl salt completely free of 2-aminoethyl hydrogen sulfate.

The invention therefore provides a substantially pure compositionconsisting essentially of viloxazine or a pharmaceutically acceptablesalt thereof. The term “substantially pure” refers to compositionscontaining essentially only the active pharmaceutical ingredient andless than about 1.5 μg (or preferably less than about 0.5 μg) of anygenotoxic impurity per expected human daily dosage, and they aretherefore suitable for use in the preparation of pharmaceutical dosageforms intended for human consumption. Further, the term “substantiallypure” refers to compositions containing at least about 99% (or morepreferably at least about 99.5%, or even more preferably at least about99.9% to about 99.99%) by weight of the active pharmaceuticalingredient. Even further, the term “substantially pure” refers tocompositions containing less than about 2.5 ppm (or more preferably lessthan about 1.5 ppm, or even more preferably less than about 1 ppm) ofany impurity. In this context, an “impurity” refers to reactionside-products or residual reagents or undesirable products thereof,which may remain in the active pharmaceutical ingredient aftersynthesis. Also, the “substantially pure” compositions referred toherein preferably contain only the active pharmaceutical ingredients asthe principal or the sole physiologically or pharmacologically activecomponent.

As used herein, the term “genotoxic” refers to compounds or substancesthat are suspected to, or have demonstrated to, induce geneticmutations, chromosomal breaks and/or chromosomal rearrangements, whichcan result in cancer.

A typical dosage of viloxazine, provided in the dosage formulation asthe hydrochloride salt, is about 1 mg to about 1000 mg per day, e.g.,about 50 mg to about 750 mg per day, alternatively, about 100 mg toabout 600 mg per day, or alternatively about 150 mg to about 300 mg perday.

By way of example, a “substantially pure” composition of viloxazine (ora pharmaceutically acceptable salt thereof) contains less than about 2.5ppm epichlorohydrin, less than about 2.5 ppm 1-(2-ethoxy-phenoxy)-2,3epoxypropane, and less than about 5 ppm of 1-aminoethyl hydrogen sulfateper daily dosage. By way of further example, a “substantially pure”composition of viloxazine (or a pharmaceutically acceptable saltthereof) contains less than about 0.8 ppm of epichlorohydrin, less thanabout 0.2 ppm of 1-(2-ethoxyphenoxy)-2,3 epoxypropane, and less thanabout 1.7 ppm of 2-aminoethyl hydrogen sulfate per daily dosage. Asmentioned above, alcohol esters of 2-aminoethyl hydrogen sulfate are notbeing formed in any embodiments of the present invention.

In another important aspect, the current invention is directed towardsthe unexpected discovery by the inventors of the previously unidentifiedpolymorphic forms of viloxazine salts, such as HCl salt. Previouslyunknown polymorphs of viloxazine were separated through series of singleand multi-solvent crystallizations using fast and slow coolingprocedures as well as slurry experiments in water and various organicsolvents. Various forms of viloxazine HCl were also prepared bycontrolling the process or conditions, such as addition sequence ofsolvents, speed of HCl salt formation, temperature, agitation, time, andother variables. New polymorphs were characterized trhough XRPD, DSC,TGA, IC, Raman, optical microscopy, ¹H NMR and moisture sorptionanalysis.

In one embodiment of the invention, unique crystalline forms ofviloxazine were separated through the single-solvent crystallization inthe solvent selected from water, acetic acid, methanol (MeOH), ethanol(EtOH), dimethylformamide (DMF), and N-methylpyrrolidone (NMP).

In a further embodiment of the invention, unique crystalline forms ofviloxazine were separated through binary-solvent crystallizations usinga primary solvent selected from acetic acid, methanol (MeOH), ethanol(EtOH), dimethylformamide (DMF), and N-methylpyrrolidone (NMP) and ananti-solvent selected from acetonitrile, etyl acetate, acetone,methyl-t-butyl ether, tetrahydrofuran, toluene, dicloromethane (DCM) andheptan. Water may also be used as a primary solvent. In this case, theanti-solvent may be selected from methanol, ethanol, isopropyl alcohol(IPA), acetone, tetrahydrofuran (THF), dioxane, acetonitrile,dimethylformamide (DMF), and N-methylpyrrolidone (NMP). Two of thesepolymorphic forms of viloxazine HCl salt are designated here asanhydrous Form A and anhydrous Form B. Polymorph Form A is characterizedby XRPD pattern and peaks and Raman spectrum and peaks as shown in FIG.6 and FIG. 9; polymorph Form B is characterized by XRPD pattern andpeaks and Raman spectrum and peaks as shown in FIG. 7 and FIG. 10.Physiochemical characterizations of the anhydrous Form A and anhydrousForm B of viloxazine HCl are shown in Example 45.

The inventors have also discovered that the polymorphic Forms A and Bcan be converted from one to another. Solvent composition can be asingle solvent, a binary solvent system, a tertiary solvent system, aquaternary solvent system and so on. Different types of solvents, ratiosof different solvents, ratio of solvents to viloxazine or viloxazinesalt can be used to prepare or control or convert the forms. Variouspolymorphic forms of viloxazine salts including HCl salt having very lowlevels of impurities, especially toxic including genotoxic impurities,thus can be prepared, controlled or converted by the said polymorphforms preparation methods, or by combinations of the said syntheticmethods, isolation and purification methods and the said polymorph formspreparation methods.

The non-excluding examples for the preparation of anhydrous Form A andanhydrous Form B of viloxazine HCl are given in Examples 20, 24, and 28through 42. Stability of the said polymorphic forms is given in Examples43-45.

In yet another aspect of the current invention, methods of synthesis ofthe main metabolites of viloxazine are provided. Compounds of Formula 6and their salts thereof can be prepared through intermediates of Formula7 (below).

wherein, R¹, R², and R³ are substituted or unsubstituted alkyl, alkenyl,alkynyl, aryl, arylalkyl, alkoxy, aryloxy, alkenoxy, alkynoxy, hydroxyl,halo, nitro, nitroso, carbonyl, carboxyl, amino, carboxamido, hydrogen,imino, cyanato, isocyanato, cyano, isocyano, pyridyl, pyrrolidyl, thio(thiol, substituted thio —S—R), disulfide (—S—S—H, —S—S—R), sulfonyl,sulfo, sulfinyl, thiocyanato groups; R⁴ is substituted or unsubstitutedalkyl, alkenyl, alkynyl, aryl, arylalkyl. carbonyl, hydrogen, pyridyl,pyrrolidyl groups; R⁵ is a substituted or unsubstituted alkyl (e.g.,benzyl herein is a substituted alkyl), alkenyl, alkynyl, aryl, alkoxy,aryloxy, alkenoxy, alkynoxy, hydroxyl, halo, nitro, nitroso, carbonyl,carboxyl, amino, carboxamido, hydrogen, imino, cyanato, isocyanato,cyano, isocyano, pyridyl, pyrrolidyl, thio (thiol, substituted thio—S—R), disulfide (—S—S—H, —S—S—R), sulfonyl, sulfo, sulfinyl,thiocyanato group, or ═O. R¹, R², R³, R⁴ and R⁵ used hereafter have thesame meaning as described in Formula 6.

Precursors, pre-metabolites, and metabolites of viloxazine can beprepared by the methods disclosed herein. The precursors can be furtherconverted to metabolites of vilozaxine. For example, Compound E whereY=OH can be oxidized to form Compound D where Y=OH. Further, suchcompounds can be reacted or converted to produce other desirablederivatives (such as by glucuronidation on the OH groups of compoundsdisclosed herein). Exemplary embodiments of the current inventivemethods and compounds are further illustrated in the non-limitingexamples below. Some exemplary compounds A-E, illustrated below, inaccordance with Formula 6 can thus be prepared:

Compounds of Formula 7 can be prepared from the corresponding compoundsof Formula 8, which is illustrated below:

For example, Epoxide II (Formula 7) can be prepared by reactingcompounds of Formula 8 with epichlorohydrin under conditions similar tothose described for viloxazine preparation above. Optionally, Epoxide IImay be reacted with a compound of Formula 9 or Formula 10 in thesynthesis of the desired compound of Formula 6.

Further, the novel intermediate of Formula 11, illustrated below, can beprepared under the same conditions as those disclosed for the viloxazinesynthesis.

EXAMPLES Example 1 Epoxide 1 Preparation in the Presence of a Solventand a Phase-Transfer Catalyst

Epichlorohydrin (4.0 eq.), potassium carbonate (powdered, 3.0 eq.), andtetrabutylammonium hydrogen sulfate (0.05 eq.) were charged to a cleanreaction vessel and stirred to a uniform slurry. 2-Ethoxyphenol (1.0eq.) dissolved in tert-butyl methyl ether (MTBE; 1.6 vol) was charged tothe vessel. The reaction mixture was heated to 55° C., and stirred for aminimum of 16 hours (overnight). The reaction was then diluted with MTBE(6.25 vol) and quenched with water. The water layer was extracted threetimes using MTBE (2.1 vol), dried over sodium sulfate (1.0 wt/wt) andcharcoal (0.05 wt/wt), filtered, and concentrated under reduced pressureto obtain an oil. The oil was co-evaporated with toluene multiple timesto remove excess epichlorohydrin. This procedure resulted in crudeyields of 98+%, and purity of 80-90% as determined by HPLC analysis.

Example 2 Epoxide 1 Preparation in the Presence of a Solvent and aPhase-Transfer Catalyst

Near 100% yield and much greater purity of Epoxide 1 was achieved bylimiting side reactions formed by the hydroxide ion by using aphase-transfer catalyst (“PTC”), a base, and a solvent. Further, the PTCreaction went to completion and proceeded to work-up much faster. Thisreaction utilized 2-ethoxyphenol (1 eq.), epichlorohydrin (4 eq.), andpotassium carbonate powder (2 eq.), in MTBE (1 mL/g). The phase-transfercatalyst was tetrabutylammonium hydrogen sulfate (See Table 1 below).

TABLE 1 Step 1 development-PTC results Batch Size Amount of Final Purity(2-Ethoxyphenol) Product/Yield by HPLC 1000 g 1803 g/128.2% 88.4%  500 g698 g/99.3% 88.1%

The median yield for the PTC reactions was 99+%, with median purity byHPLC was measured at 88.2%. Excess epichlorohydrin was removed byco-evaporation with toluene. The reaction was stable in MTBE at roomtemperature or −20° C. over night. The crude material was stable at 53°C. during co-evaporation with toluene and stable at room temperature or−20° C. overnight.

Example 3 Epoxide 1 Preparation in the Presence of a Solvent and aPhase-Transfer Catalyst

An appropriately sized three-neck round bottom flask was equipped with amechanical stirrer, thermocouple with display, nitrogen inlet,condenser, and drying tube in a heating mantle. The following materialswere charged into the flask: epichlorohydrin (1340 g, 14.48 mol, 1132mL, 4.0 eq.), powdered potassium carbonate (1000 g, 7.24 mol, 2.0 eq.),and tetrabutylammonium hydrogen sulfate (61 g, 0.18 mol, 0.05 eq.). Themixture was stirred to an even slurry. Further, 2-ethoxyphenol (500 g,3.92 mol, 459 mL, 1.0 eq.) in methyl tert-butyl ether (MTBE) (500 mL)were charged to the reaction mixture. The flask was heated to 45° C. for48 hours with stirring. The reaction for checked completeness by HPLC.The starting material had Rt 8.875 minutes, product had Rt 10.025minutes, intermediate had Rt 10.852 minutes, and an impurity had a Rt13.975 minutes. The reaction was considered complete when a combinedtotal of <5% of the starting material and intermediate were present inthe reaction mixture. The contents were diluted with MTBE (1 L) andfiltered the mixture through a glass fiber filter pad to removeinsolubles. The organic mixture was washed with brine (3×800 mL) and thesolution treated with charcoal and magnesium sulfate for 30 minutes. Thesolution and concentrate were filtered on a rotoevaporator at 35° C. Theresidue was co-evaporated with toluene (2×1 L). The product was anorange oil. 698 g, 99.3%, HPLC: 88.1%.

Example 4 Epoxide 1 Preparation in the Presence of a Solvent and aPhase-Transfer Catalyst and Conversion into Viloxazine Base

A 6.1 kg batch of 2-ethoxyphenol was produced using 4.0 eq. ofepichlorohydrin and 2.0 eq. of potassium carbonate at 45° C. provided a60% conversion after 5 days. An additional 0.5 eq. of a phase-transfercatalyst (i.e. a benzyltriethylammonium salt) was added and thetemperature was increased to 50° C. The following day, 82.5% conversionwas obtained and the reaction was deemed complete. Assumed yield was8.55 kg (100%), HPLC A %: 83.6% and G.C.: 62.4%. The intermediate wascarried directly to the next step using 8.4 eq. of aminoethyl hydrogensulfate and 30.0 eq. of potassium hydroxide (KOH). Adding the reactionmixture to the KOH solution resulted in 17% conversion and a recovery of891 g of crude viloxazine after work up.

Example 5 Epoxide 1 Preparation in the Presence of a Solvent and aPhase-Transfer Catalyst and Conversion into Viloxazine Base

A 6.1 kg batch of 2-ethoxyphenol was produced using 4.0 eq. ofepichlorohydrin and 2.0 eq. of potassium carbonate at 50° C. provided a63.7% conversion after two days. An additional 0.5 eq. of a phasetransfer catalyst (i.e., a benzyltriethylammonium salt) was added andthe following day 79.7% conversion was achieved and the temperature wasincreased to 55° C. The following day 80.2% conversion was obtained andthe reaction was deemed complete. The crude oil was co-evaporated withtoluene at 52° C. to remove excess epichlorohydrin. Yield was 7.2 kg,HPLC A %: 76.8%. The intermediate was carried directly to the next stepusing 8.4 eq. of aminoethyl hydrogen sulfate and 30.0 eq. of potassiumhydroxide. Adding the intermediate mixture to 10.0 eq of KOH solutionand stirring at 57° C. for 4 hours before adding the remaining 20.0 eq.of KOH solution resulted in 54.0% conversion the next day and a recoveryof 4686 g of crude viloxazine after work up.

Example 6 Epoxide 1 Preparation in the Presence of a Solvent and aPhase-Transfer Catalyst and Conversion into Viloxazine Base

A 9.6 kg batch of 2-ethoxyphenol was produced using 4.0 eq. ofepichlorohydrin and 3.0 eq. of potassium carbonate at 55° C. provided89.6% conversion after 24 hours. Assumed yield was 13.5 kg (100%), HPLCA %: 74.6%. The intermediate was carried directly to the next step using8.4 eq. of aminoethyl hydrogen sulfate and 30.0 eq. of potassiumhydroxide. Adding the intermediate mixture to 10.0 eq. of KOH solutionand stirring at 57° C. for 4 hours before adding the remaining 20.0 eq.of KOH solution resulted in 52.3% conversion the next day and a recoveryof 4.7 kg of crude viloxazine after work up.

Example 7 Epoxide 1 Preparation in the Presence of a Solvent and aPhase-Transfer Catalyst and Conversion into Viloxazine Base

A 12 kg batch of 2-ethoxyphenol was produced using 4.0 eq. ofepichlorohydrin and 3.0 eq. of potassium carbonate at 55° C. provided77.6% conversion after 24 hours. Assumed yield was 16.8 kg (100%), HPLCA %: 79.7%. 9.7 kg of the intermediate was carried directly to the nextstep using 8.4 eq. of aminoethyl hydrogen sulfate and 30.0 eq. ofpotassium hydroxide. Adding the intermediate mixture to 10.0 eq. of KOHsolution and stirring at 57° C. for four hours before adding theremaining 20.0 eq. of KOH solution resulted in 52.3% conversion the nextday and a recovery of 2.6 kg of crude viloxazine after work up.

Example 8 Epoxide 1 Preparation in the Presence of a Solvent and aPhase-Transfer Catalyst

The 2-ethoxyphenol may require melting prior to use. The followingprocedure was performed: into a clean dry 50 gallon glass lined reactorepichlorohydrin (25.7 kg), potassium carbonate (28.8 kg) andtetrabutylammonium sulfate (1.18 kg) were charged under nitrogen withstirring. This mixture was stirred to an even slurry. 2-ethoxyphenol(9.6 kg) dispersed in MTBE (15 L) was added to the slurry. The resultingslurry to was heated 55° C. and held at this temperature for a minimumof 16 hours. The reaction mixture may be monitored by HPLC if desired,but based on historical data, after a minimum of 16 hours the reactionis complete. The reaction mixture was checked for reaction completion byHPLC. The sample was worked-up by adding water (2.0 vol.) and MTBE (2.0vol.), mixing well, and separating organic layer for HPLC (PRLC6-230nm). Starting material Rt 8.875 minutes, product Rt10.025 minutes,intermediate Rt 10.025 minutes, and an impurity Rt 13.975 minutes. Thereaction was deemed complete when a combined total of <5% of startingmaterial and intermediate were present in the reaction mixture. MTBE (60L) was added and stirred 15 minutes. Water (30 L) was added and stirredfor a minimum of 30 minutes. Stirrer stopped and layers allowed toseparate for a minimum of 15 minutes. Bottom aqueous phase removed (heldfor back extraction This step was repeated three times. The aqueousphase was back extracted with MTBE (20 L) and stirred for a minimum of30 minutes; layers allowed to separate for a minimum of 15 minutes.Bottom aqueous phase removed (this may be disposed of properly). 25%aqueous sodium chloride (30 L) was added to the combined organics andstirred for a minimum of 30 minutes; layers allowed to separate for aminimum of 15 minutes. Bottom aqueous sodium chloride phase removed(this may be disposed of properly). Sodium sulfate (4.0 kg) was addedand stirred a minimum of one hour. Activated carbon (0.5 kg) was addedand stirred a minimum of one hour. Filtered off the sodium sulfate andcarbon and washed with MTBE (10 L). The resulting filtrate was strippedto a thick oil under vacuum at 35° C. and co-evaporated with toluene(3×4 L) under vacuum to a pot temperature of 52° C. yield/13.6 kg (100%)HPLC Area %: 74.6% G.C.: 51.5%. Material may be carried directly to thenext step.

Example 9 Epoxide 1 Preparation in the Presence of a Solvent, aPhase-Transfer Catalyst and an Additional Catalyst

Provide 1 eq. of 2-ethoxyphenol, 1.0-2.0 eq. of epichlorohydrin, 2 eq.of powdered potassium carbonate powder (325 mesh), 0.001-0.05 eq. oftetrabutylammonium salt Q⁺X⁻ (X=HSO₄ or Cl), 0.0005-0.025 eq. ofpotassium iodide (catalyzes the process via the Finkelstein reactionwhen used in the amount that doesn't exceed the amount of Q⁺X⁻; use ˜50%in regards to Q⁺). If amount of I⁻ is equal or greater to the amount ofQ⁺X⁻, a strong inhibition of the reaction is observed; 1-10 vol. ofacetonitrile (solvent to dissolve the tetraalkylammonium salt of thesubstrate). It is recommended to use a minimal volume of solvent to makethe reaction mixture stirrable to ensure the highest reaction rate (DCMis not recommended as the solvent because it reacts with phenolates);20-50° C., 12-48 hrs. Use the lowest temperature possible to ensurereasonable reaction rate and minimize unwanted side reactions. Typicalwork-up conditions are similar to the described above.

Example 10 Epoxide 1 Preparation at Low Temperature

The reaction of 2-ethoxyphenol and epichlorohydrin at room temperaturein presence of sodium hydroxide solution was improved. In one instance,the reaction of 2-ethoxyphenol (1 eq.) and epichlorohydrin (1.5 eq.) inwater and 50% NaOH solution (1.2 eq.) was stirred at room temperatureover night. The second step took the intermediate from the first stepand coupled it with 2-aminoethyl hydrogen sulfate (2.12 eq.) in 50% NaOH(4.24 eq.), water, and ethanol. The overall yield using this route was amedian of 19.2% after recrystallization to achieve the desired purity.Experiments were conducted to maintain the reaction mixture at <10° C.during the overnight stir period (See Table 3, below).

TABLE 2 Step I Experimental Conditions at Ambient Temperature OvernightBatch Size Amount of Purity (2-Ethoxyphenol) Intermediate/Yield by HPLC200 g 257 g/84.8% 57.3%

TABLE 3 Step I Experimental Conditions at 5-8° C. Batch Size Amount ofPurity (2-Ethoxyphenol) Intermediate/Yield by HPLC 1000 g 1499 g/107%66.2%  200 g  277 g/91.4% 48.5%  200 g  275 g/90.7% 55.8%This resulted in an increase in Step I yield. However, the best initialpurity results remained at only 48.5% to 66.2% with multiple sideproducts forming.

Example 11 Epoxide 1 Preparation Through the Finkelstein Reaction

Alternatively, Epoxide 1 can be prepared by using a Finkelstein reactioncatalyst, such as KI. The base can be used as a solid. An aproticsolvent can be used. 1 eq. of 2-ethoxyphenol, 1.0-2.0 eq. ofepichlorohydrin, 2 eq. of potassium carbonate powder (˜325 mesh), 0.2eq. of potassium iodide (which catalyzes the process via the Finkelsteinreaction), 5 vol. of DMF (polar aprotic solvent to dissolve thepotassium salt of the substrate and make it reactive), 20-30° C., 12-48hrs. Typical work-up conditions include the following steps: (1) Pourthe reaction mixture onto a stirred mixture of heptane (8 vol.), EtOAc(2 vol.) and water (15 vol.); (2) stir the mixture over 5-10 minutes,allow the layers to separate, and collect the organic layer; (3) extractthe aqueous layer with a mixture of heptane (4 vol.) and EtOAc (1 vol.);(4) combine all organic layers and wash with water (3×3 vol.) to removeany residual DMF; (5) dry the organic solution with MgSO₄ (0.2 vol) over10-15 minutes with stirring; (6) filter off MgSO₄ and rinse the filtercake with a mixture of heptane (0.8 vol.) and EtOAc (0.2 vol.); (7)concentrate the filtrate under reduced pressure at 35-45° C. to aminimal stirring volume; (8) co-evaporate the residue with heptane (2×2vol.) under reduced pressure at 40-45° C. to remove residual EtOAc (ifneeded); and (9) recrystallize the residue from a suitable solvent (ifapplicable) or use directly in the next step as is.

Example 12 Epoxide 1 Preparation in a 2-Stage PTC Process

The following steps were performed: equipping a 1 L three-neckglass-reactor with a mechanical stirrer, thermocouple with display,nitrogen inlet, condenser, and under vacuum distillation system and thenperforming the following: Under stirring, charging to the flaskepichlorohydrin (313.44 g, 3.3878 mol, 265.36 mL, 8.05 eq.) and2-ethoxyphenol (58.17 g, 0.4210 mol, 53.37 mL, 1.0 eq.). Heating theflask to 60° C. Adding solid benzyl triethylammonium chloride (9.65 g,0.0424 mol, 0.1 eq.) and heating the flask to 70° C. for 6 h. Checkingthe reaction for completeness by TLC. Preparing the sample by taking a 1mL aliquot of the reaction mixture and diluting to a clear solution withacetone to obtain a 5% solution. Using 7:3 heptane/ethyl acetate or theeluent. The starting material was Rf 0.77 and the intermediate was Rf0.58. The reaction was deemed complete when there was no startingmaterial in the reaction mixture. Concentrating the reaction mixture at70° C. under vacuum. Cooling down to 45° C. Diluting the residue withtoluene (145.46 g). Adding dropwise in 20 min NaOH aq. 30% (73.27 g,0.5495 mol, 1.305 eq.) and stirring at 45° C. for 1 h after addition.Washing the organic mixture with water (3×75.6 g) and concentratingunder vacuum at 70° C. The product was a pale yellow oil which was usedwithout any further purification in the next step. 84.63 g, 103.5%, GC:97.3% area.

Example 13 Conversion of Epoxide 1 into Viloxazine Base

2-Aminoethyl hydrogen sulfate (8.4 eq.) was dissolved in 60% aq.potassium hydroxide solution (10.0 eq.). After a uniform solution wasachieved, the Step I intermediate (Epoxide 1, 1 eq.) diluted in methanol(9.8 vol) was added. The reaction mixture was stirred at 55° C. for 4hours, 60% aq. potassium hydroxide solution (20.0 eq.) was added andthen stirred at 55° C. for a minimum of 16 hours (overnight). Thereaction was deemed complete by HPLC when the reaction progress showed50-55% of desired product. The reaction was then worked up as describedin Step IIa below. This exemplary procedure produces averaged yields of30-40% with purity of crude product >80% by HPLC.

Exemplary work-up steps of this method were as follows: Stripped themethanol to a pot temperature of 50° C. under vacuum. Added water (20.8vol) to the thick slurry. Transferred the slurry to water (72.9 vol.).Added MTBE (9.4 vol) and stir 15 minutes. Stopped stirrer and allowedlayers to separate for a minimum of 15 minutes. Separated phases (holdorganic phase). If un-dissolved salt remains, added recorded amount ofwater to help dissolve the salt. If resultant solution was hazy,filtered the resultant solution through a filter funnel or centrifuge toallow for better separation. Extracted aqueous phase with MTBE (9.4 vol)and stirred 15 minutes. Stopped stirrer and allowed layers to separatefor a minimum of 15 minutes. Separated phases (held organic phase).Extracted aqueous phase with MTBE (9.4 vol) and stirred 15 minutes.Stopped stirrer and allowed layers to separate for a minimum of 15minutes. Separated phases (held organic phase). Extracted aqueous phasewith MTBE (9.4 vol) and stirred 15 minutes. Separated phases. Checkedaqueous phase for the presence of product. Further extractions may havebeen required. Combined the organics and washed with 20% brine solution.Separated layers. Cooled the organics to 5-10° C. Extracted the combinedorganics with 6 M HCl (40 L). Stirred for 15 minutes. Stopped stirrerand allowed layers to separate for a minimum of 15 minutes. Separatedphases (held aqueous phase). Extracted the combined organics with 6 MHCl (20 L). Stirred for 15 minutes. Stopped stirrer and allowed layersto separate for a minimum of 15 minutes. Separated phases (held aqueousphase). Extracted the combined organics with 6 M HCl (20 L). Stirred for15 minutes. Stopped stirrer and allowed layers to separate for a minimumof 15 minutes. Separated phases. Checked organic phase for the presenceof product. Further extractions may have been required.

Slowly added 50% sodium hydroxide to the combined aqueous phase at <25°C. to a pH>12. Extracted aqueous phase with MTBE (30 L) and stirred 15minutes. Stopped stirrer and allowed layers to separate for a minimum of15 minutes. Separated phases (held organic phase). Extracted aqueousphase with MTBE (30 L) and stirred 15 minutes. Stopped stirrer andallowed layers to separate for a minimum of 15 minutes. Separated phases(held organic phase). Extracted aqueous phase with MTBE (30 L) andstirred 15 minutes. Stopped stirrer and allowed layers to separate for aminimum of 15 minutes. Separated phases (held organic phase). Extractedaqueous phase with MTBE (30 L) and stirred 15 minutes. Stopped stirrerand allowed layers to separate for a minimum of 15 minutes. Separatedphases (held organic phase). Combined the organics and washed with 20%brine solution. Added sodium sulfate to the combined organics andstirred a minimum of one hour. Added activated carbon (0.05 eq.) andstirred a minimum of one hour. Filtered off the sodium sulfate andcarbon and washed with MTBE (1.0 vol.). Stripped the resulting filtrateto a thick oil under vacuum at 35° C. Added isopropanol (1.45 vol.) tothe oil. Added conc. HCl at a pot temperature <25° to a pH 1. Addedethyl acetate (5.6 vol.) to the mixture. Cooled to −5° C. and stirredfor a minimum of 12 hours. Filtered the solid product. Washed theresulting solids with 0° C. isopropanol (2×0.78 vol.). Further washedthe solids with ethyl acetate (2×1.05 vol.). Oven dried the solids to aconstant weight at 35° C. under vacuum.

Example 14 Conversion of Epoxide 1 into Viloxazine Base

Step II a reaction was improved by reacting of 1 eq. of Epoxide 1 with2-aminoethyl hydrogen sulfate (8.4 eq.) in a large molar excess ofpotassium hydroxide solution (30 eq.). See Table 4 below.

TABLE 4 Step IIa-Experimental Results Batch Size Amount of Final Purity(Step 1 int.) Product/Yield by HPLC  260 g 114 g/31.1% 99.2% 1406 g 788g/39.8% 99.1%  277 g 127 g/32.4% 99.1%

Example 15 Conversion of Epoxide 1 into Viloxazine Base

An appropriately sized three-neck round bottom flask was equipped with amechanical stirrer, thermocouple with display, and a nitrogen inlet andplaced initially in a cooling tub. Potassium hydroxide (802 g, 14.30mol, 10 eq.), water (500 mL) and 2-aminoethyl hydrogen sulfate (1695 g,12.01 mol, 8.3 eq.) were charged in and stirred to an even solutionunder a nitrogen atmosphere, maintain the temperature under 55° C.1-(Ethoxyphenoxy)-2,3-epoxypropane (starting intermediate) (277 g, 1.43mol, 1.0 eq.), and methanol (2.2 L) were charged to the flask and heatedto 55° C. for 4 hours. Potassium hydroxide (1604 g, 28.60 mol, 20 eq.)in water (1.1 L) was charged to the flask and stirred at 55° C. for 16hours. The reaction was checked for completeness by TLC. The sample wasprepared by taking a 0.5 mL aliquot of the reaction mixture and dilutingto a clear solution with water, then extracting with ethyl acetate. Theorganic layer was compared to the starting intermediate from Step Iusing 1:1 heptane/ethyl acetate as an eluent. The starting material wasR_(f) 0.7 and the product was R_(f) 0.0. The reaction was deemedcomplete when there is no starting material in the reaction mixture. Thereaction mixture was concentrated to remove methanol.

Example 16 Preparation of 2-[(2-ethoxyphenoxy)methyl]morpholinehydrochloride (Viloxazine HCl)

Exemplary Procedure included the following: (1) Charging to a clean 100gallon stainless steel reactor water (57.9 L) with stirring undernitrogen. (2) Adding potassium hydroxide pellets (78.0 kg) at <50° C.(3) Cooling solution to 20-25° C., dropped out of reactor and held forstep 10; labeling accordingly. (4) Charging the stainless steel reactorwith water (26.2 L). (5) Adding potassium hydroxide pellets (38.9 kg) at<50° C. (6) Adding 2-aminoethyl hydrogen sulfate (82.4 kg). (7) Heatingthe resulting mixture to 55° C. (8) Adding to the oil from previousstep, 1-(ethoxyphenoxy)-2,3-epoxypropane, methanol, (94.5 L) andtransferring to the mixture, step 7 (below), in the stainless steelreactor at 55° C. (9) Stirring at 55° C. for 4 hours. (10) Adding theprepared potassium hydroxide solution from step 3 (above) to thereaction mixture at less than 60° C. (11) Stirring the mixture at 57° C.for a minimum of 12 hours. (12) Sampling the reaction mixture forreaction completion check by HPLC. Working-up sample by adding water(8.0 vol.) and MTBE (2.0 vol.), mixing well and separating organic layerfor HPLC (PRLC 6-230 nm). Starting material Rt 10.0 minutes, product Rt7.0 minutes, intermediate Rt 10.025 minutes, and impurities at Rt 13.975minutes and Rt 6.4 minutes. (13) Typically 45-55% product was present.Stirring longer has not improved the conversion percentage. The HPLCmonitoring is recommended for informational purposes only, as thereaction has proven to proceed to a point of completion after 12-16hours of heating and will not progress further even with additionalreagents, base, or time. (14) Stripping off the MeOH to a pottemperature of 50° C. under vacuum. (15) Adding water (200 L) to thethick slurry. (16) Transferring the slurry to water (700 L). Solutionwill occur. (17) Adding MTBE (90 L) and stirring 15 minutes. (18)Stopping stirrer and allowing layers to separate for a minimum of 15minutes. (19) Separating phases (held organic phase). (20) Extractingaqueous phase with MTBE (90 L) and stirring 15 minutes. (21) Stoppingstirrer and allowing layers to separate for a minimum of 15 minutes.(22) Separating phases (held organic phase). (23) Extracting aqueousphase with MTBE (90 L) and stirring 15 minutes. (24) Stopping stirrerand allowing layers to separate for a minimum of 15 minutes. (25)Separating phases (held organic phase). (26) Extracting aqueous phasewith MTBE (90 L) and stirring 15 minutes. (27) Separating phases.Checking aqueous phase for the presence of product. Further extractionsmay have been requiring. (28) Extracting the combined organics with 6 MHCl (30 L). (29) Stirring for 15 minutes. (30) Stopping stirrer andallowing layers to separate for a minimum of 15 minutes. (31) Separatingphases (held aqueous phase). (32) Extracting the combined organics with6 M HCl (15 L). (33) Stirring for 15 minutes. (34) Stopping stirrer andallowing layers to separate for a minimum of 15 minutes. (35) Separatingphases (held aqueous phase). (36) Extracting the combined organics with6 M HCl (15 L). (37) Stirring for 15 minutes. (38) Stopping stirrer andallowing layers to separate for a minimum of 15 minutes. (39) Separatingphases. Checking organic phase for the presence of product. Furtherextractions may have been required. (40) Adding 50% sodium hydroxide (20L) to the combined aqueous phase at <25° C. to a pH>12. (41) Extractingaqueous phase with MTBE (30 L) and stirring 15 minutes. (42) Stoppingstirrer and allowing layers to separate for a minimum of 15 minutes.(43) Separating phases (held organic phase). (44) Extracting aqueousphase with MTBE (30 L) and stirring 15 minutes. (45) Stopping stirrerand allowing layers to separate for a minimum of 15 minutes. (46)Separating phases (held organic phase). (47) Extracting aqueous phasewith MTBE (30 L) and stirring 15 minutes. (48) Stopping stirrer andallowing layers to separate for a minimum of 15 minutes. (49) Separatingphases (held organic phase). (50) Extracting aqueous phase with MTBE (30L) and stirring 15 minutes. (51) Stopping stirrer and allowing layers toseparate for a minimum of 15 minutes. (52) Separating phases (heldorganic phase). (53) Adding sodium sulfate (8.0 kg) to the combiningorganics and stirring a minimum of 1 hour. (54) Adding activated carbon(0.5 kg) and stirring a minimum of 1 hour. (55) Filtering off the sodiumsulfate and carbon and washing with MTBE (10 L). (56) Stripping theresulting filtrate to a thick oil under vacuum at 35° C. (57) Addingisopropanol (14 L) to the oil. (58) Adding conc. HCl (3.1 L) at a pottemperature <25° to a pH 1. (59) Adding ethyl acetate to the mixture.(60) Cooling to −5° C. and stirring for a minimum of 12 hours. (61)Filtering the solid product. (62) Washing the resulting solids with 0°C. isopropanol (2×7.5 L). (63) Further washing the solids with ethylacetate (2×10 L). (64) Oven drying the solids to a constant weight at35° C. under vacuum. Crude yield: 5.6 kg; HPLC: 72.7%.

Example 17 Formation and Cyclization of Diol 1

The following was performed in a 1 liter three-neck glass-reactorequipped with a mechanical stirrer, thermocouple with display, nitrogeninlet, condenser, and under vacuum distillation system: Under stirring,charging to the flask crude 1-(ethoxyphenoxy)-2,3-epoxypropane(intermediate) (84.63 g.) and toluene (245 mL) to the flask and heatingto 100° C. Adding dropwise 2-benzylaminoethanol (66.01 g, 0.4365 mol,1.037 eq.) to the flask and heating at reflux for 6 hours. Checking thereaction for completeness by HPLC. The reaction was deemed complete whenthere was less than 2% starting material in the reaction mixture.Cooling down the reaction mixture to room temperature. Adding toluene(130 mL) and solid benzyltriethylammonium chloride (4.99 g, 0.0219 mol,0.052 eq.). Adding NaOH micro-pellets (104.62 g, 2.6155 mol, 6.213 eq.).The reaction mixture became very thick. After stirring 10 min at roomtemperature, slowly adding solid para-toluenesulfonyl chloride (84.71 g,0.4443 mol, 1.055 eq.) by keeping the temperature below 40° C. Stirringfor 2 h at room temperature. Checking the reaction for completeness byHPLC (Rt 8340DI=15.9′, Rt 8340Bn=17.3′). Washing the organic mixturewith water (1×507.06 g+2×130.98 g) and concentrating under vacuum at 45°C. The product was a pale yellow oil which may be used without anyfurther purification in the next step. 137.85 g, 113.5%, HPLC: 67.8%area.

Example 18 Deprotection and Crystallization of Viloxazine

The following was performed in a 1 liter three-neck glass-reactorequipped with a mechanical stirrer, thermocouple with display, nitrogeninlet, condenser, and under vacuum distillation system: Under stirring,charging to the flask crude N-benzylviloxazine (intermediate) (137.85g.), ethanol (295 mL), HCl aq. 32% (135.6 mL), H₂O (135.6 mL) and Pd/C3% (75.84 g.). Heating the flask to 60° C. Bubbling H₂ in the reactionmixture (time of the bubbling depends on the size of the H₂ bubbles:with very small bubbles, reaction is finished after 2 h). Checking thereaction for completeness by HPLC (Rt viloxazine=11.7′). Concentratingthe reaction mixture under vacuum to dryness. Adding to the residueisopropanol (290 mL) and water (60 mL). Heating the mixture to 80° C.until solution occurs. Slowly cooling the solution to 50° C. and slowlyadding ethyl acetate (480 mL). Cooling the mixture to 0-5° C. for atleast 3 h. Filtering the product and washing with ethyl acetate (2×50mL). Vacuum oven drying the solids at 80° C. to constant weight. 52.24g, 57.0%, HPLC: 99% assay.

Example 19

Viloxazine HCl (6089 g) was dissolved in water (10 vol.). Free-basing ofthe salt was performed by slow addition of 50% NaOH (temp. <25° C.) tothe solution until pH 11 is reached. Once the free base was formed, itwas extracted three times with methyl tert-butyl ether (MTBE, 5 vol. perextraction). The combined MTBE extracts were then washed with water (1.5vol.). The resultant organics were then dried over sodium sulfate (1.0eq.), filtered through an in-line cartridge, and the sodium sulfatewashed with MTBE (1.0 vol). The organics were then concentrated down toa thick oil.

Example 20 Conversion Between Viloxazine Base and Viloxazine Salt;Formation of Polymorph Form B

The residue from Example 15 was diluted with water (30 L) and extractedwith ethyl acetate (6×2 L). All organic extracts were combined andfurther extracted with 6 M HCl (3×2 L). The organic layer was checkedfor product by TLC and then discarded. The aqueous solution was adjustedto pH 12 with 50% NaOH. The basic solution was extracted with MTBE (3×3L). All organic extracts were combined and washed with brine (1 L), andthen treated with charcoal and magnesium sulfate for 30 minutes. Themixture was filtered through a glass fiber filter pad and concentratedon a roto-evaporator at 45° C. to give a light-colored oil. The residuewas diluted with ethyl acetate (1 L) and 12 M HCl (80 mL) in isopropanol(160 mL), and stirred for 30 minutes at 0-5° C. The product was filteredand washed with ethyl acetate (2×400 mL) and heptane (3×500 mL). Thesolids were dried in a vacuum oven at 40° C. to constant weight. 127 g,32.4%, HPLC: 94.6%.

Example 21 Recrystallization; Formation of Polymorph Form A Example 21 A

The following method was performed as needed; typically twice: Chargedisopropanol (1.5 vol.), water (0.75 vol.), and crude viloxazine HCl (1.0eq.) to a clean dry reactor with stirring under nitrogen. Heated themixture to 80° C. Solution occurred. Hot filtered the resultantsolution. Cooled the solution to 45-50° C., solids began to precipitate.Slowly added ethyl acetate (4.0 vol.). Cooled the mixture to −5°-0° C.and stirred for a minimum of 12 hours. Filtered the resulting solids.Washed the solids with 0° C. Isopropanol (2×1 vol). Washed the solidswith 0° C. ethyl acetate (2×1 vol.). Oven dried the solids to a constantweight at 35° C. under vacuum.

Example 21 B

The following method was performed as needed; typically twice: Chargedisopropanol (4.5 vol.) at 80° C. to a clean dry reactor with stirringunder nitrogen. Add water (1 vol); bring the temperature to 45-50° C.Add viloxazine. Slowly added ethyl acetate (7.0 vol.). Cooled themixture to 0-5° and stirred for a minimum of 2.5 hours. Filtered theresulting solids. Washed the solids with ethyl acetate (2×1 vol.). Ovendried the solids to a constant weight at 35° C. under vacuum.

The resultant product was white to off-white powder comprising not morethan 2.1 ppm of 1-(ethoxyphenoxy)-2,3-epoxypropane and not more than 2.1ppm of epiclorhydrine. The product was identified through IR spectrum,HPLC and XRPD (FIG. 8).

Example 22 Conversion Between Viloxazine Base and Viloxazine Salt, andRecrystallization

Purification according to methods described in Examples 19 and 21afforded substantially pure viloxazine HCl with extremely low levels ofepichlorohydrin, 1-(ethoxyphenoxy)-2,3-epoxypropane and 2-aminoethylhydrogen sulfate. No trace of aminoethyl hydrogen sulfate ester of analcohol was observed. Typical analytical results for exemplary batchesprovided by the methods of this Example are provided in Table 5, below.

TABLE 5 Batch Analysis Summary 2-aminoethyl Epichloro-1-(ethoxyphenoxy)- hydrogen hydrin 2,3-epoxypropane sulfate Sample 1 ofGMP 0.6 ppm None Detected None Detected lot used for clinical trialmaterial manufacturing

Example 23 Formation of Polymorph B

The oil from Example 19 was dissolved in isopropanol (IPA, 1.0 vol),adjusted to pH=1 with conc. HCl (2 vol), and ethyl acetate added (EtOAc,3.7 vol). The resultant slurry was then cooled to −5 to 0° C., andstirred for a minimum of 12 hours. The slurry was then filtered, washedwith cold IPA (2×0.5 vol), and then cold EtOAc (2×1.5 vol). The isolatedsolid was then dried under vacuum at 35-40° C.

Example 24 Formation of Polymorph A; Conversion from B to A

Vilozaxine HCl (crude, or in Form B) was re-dissolved in IPA (1.5 vol.)and water (0.75 vol.) at −80° C., cooled to 45-55° C., and EtOAc (4.0vol) was added. The solution was cooled to cool to −5 to 0° C., andstirred for a minimum of 12 hours. The slurry was then filtered, washedwith cold IPA (2×0.5 vol.), and then cold EtOAc (2×1.5 vol.). Theisolated solid was then dried under vacuum at 35-40° C.

Example 25

Purification steps included the following: (1) Charged isopropanol (8.3L/1.5 vol.), water (4.1 L/0.75 vol.), and crude viloxazine HCl (5.5 kg)to a clean dry 50 gallon reactor with stirring under nitrogen. (2)Heated the mixture to 80° C. Solution occurred. (3) Cooled the solutionto 50° C., solids began to precipitate. (4) Slowly added ethyl acetate(22.0 L/4 vol.). (5) Cooled the mixture to −5°-0° C. and stir for aminimum of 12 hours. (6) Filtered the resulting solids. (7) Washed thesolids with 0° C. isopropanol (5.5 L/1 vol). (8) Washed the solids withethyl acetate (2×5.5 L/2 vol.). (9) Oven dried the solids to a constantweight at 35° C. under vacuum. Yield/4.7 kg−HPLC/98.8%.

TABLE 6 Crude (g) Yield (g) HPLC 11,187 g 9088 g/81.2% 98.2%   5600 g4619 g/82.5% 98.8%   2601 g 2176 g/83.6% 98.4%

Example 26

High purity purification steps included the following: (1) Chargingisopropanol (10.2 L/1.5 vol.), water (5.1 L/0.75 vol.), and >98.0%viloxazine HCl (6.816 kg) to a clean dry 50 gallon reactor with stirringunder nitrogen. (2) Heating the mixture to 80° C. Solution occurred. (3)Cooling the solution to 50° C., solids began to precipitate. (4) Slowlyadding ethyl acetate (27.3 L/4 vol.). (5) Cooling the mixture to −5°-0°C. and stirring for a minimum of 12 hours. (6) Filtering the resultingsolids. (7) Washing the solids with 0° C. isopropanol (6.8 L/1 vol). (8)Washing the solids with ethyl acetate (2×6.8 L/2 vol.). (9) Oven dryingthe solids to a constant weight at 35° C. under vacuum.

TABLE 7 Crude (g) Yield (g) HPLC 6816 g 6435 g/94.4% 99.8%

Examples 27-45

Examples 27-45, below, reflect exemplary processes and methods relatingto solvent system selected for the formation or separation of polymorphsForm A and Form B.

TABLE 8 Characterization summary for Viloxazine HCl Crystalline Forms Aand B TGA API Moisture DSC Wt. to Sorption Peaks Loss HCl (wt % at 90%Form Conditions XRPD (° C.) (wt %) 1H NMR ratio RH) A (anhydrate)binary-solvent Crystalline 188 0.0 consistent 1:0.9 Non- with MeCN asw/structure hygroscopic, anti-solvent (fast 0.25 wt % and slow cooling)B (anhydrate) Slurry in water, Crystalline 186 0.0 consistent 1:1   Non-9:1 MeCN/H2O w/structure hygroscopic, and 9:1 0.31 wt % acetone/H2O;most binary- solvent with MTBE and toluene as anti- solvents

Example 27

TABLE 9 Solvent Screen for Viloxazine HCl Drug Solvent Gravimetric ICHAmt amount Temp Soluble Solubility at ICH limit b.p. Solvent (mg) (mL)(° C.) (Visual) RT (mg/mL) class (ppm) (° C.) water 3.5 0.1 RT Yes >35 ~~ 100 acetic acid 3.1 0.1 55 Yes 6.7 3 * 115 methanol 3.2 0.1 55 Yes16.0 2 3000 65 ethanol 3.6 0.8 55 Yes 1.9 3 * 78 IPA 3.8 1.6 55 Yes 0.33 * 82 t-AmOH 3.2 1.6 55 No 0.0 ~ ~ 102 1-butanol 3.4 1.6 55 No 0.0 3 *118 DMF 2.9 0.4 55 Yes 0.6 2 880 153 acetonitrile 3.9 1.6 55 No 0.0 2410 81 MeOAc 3.8 1.6 55 No 0.0 3 * 58 EtOAc 3.2 1.6 55 No 0.0 3 * 77IPAc 2.7 1.6 55 No 0.0 3 * 89 acetone 3.6 1.6 55 No 0.0 3 * 56 MEK 3.71.6 55 No 0.0 3 * 80 MIBK 2.6 1.6 55 No 0.0 3 * 117 MTBE 3.2 1.6 55 No0.0 3 * 56 THF 3.3 1.6 55 No 0.1 2 720 66 2-MeTHF 2.6 1.6 55 No 0.0 ~ ~79 dioxane 2.6 1.6 55 No 0.0 2 380 101 toluene 3.1 1.6 55 No 0.0 2 890111 xylene 3.2 1.6 55 No 0.0 2 2170 140 DCM 2.5 4.8 40 No 0.0 2 600 40cyclohexane 3.6 1.6 55 No 0.0 2 3880 81 heptane 3.5 1.6 55 No 0.0 3 * 98NMP 3.1 0.4 55 Yes 4.9** 2 530 202

Example 28

TABLE 10 Single Solvent Crystallizations of Viloxazine HCl Using a FastCooling Profile Drug amt Amount Temp. Recovery Yield Form (mg) Solvent(mL) (° C.) Cooling Precipitation (mg) (%) [XRPD] 26.6 AcOH 0.30 75 FastYes 11.1 41.7 A 25.3 DMF 1.00 75 Fast Yes 18.4 72.7 A 25.9 NMP 1.05 75Fast Yes 16.0 61.8 A 28.8 water 0.20 75 Fast No/scr/evap n/a n/a B

Example 29

TABLE 11 Single Solvent Crystallizations of Viloxazine HCl Using a SlowCooling Profile Drug amt Amount Temp. Recovery Yield Form (mg) Solvent(mL) (° C.) Cooling Precipitation (mg) (%) [XRPD] 25.0 MeOH 0.5 60 20°C./h Yes 11.2 44.8 A 24.3 AcOH 0.3 75 20° C./h No/scr/ppt 11.0 45.3 A24.2 NMP 1.0 75 20° C./h Yes 15.1 62.4 A 29.3 water 0.2 75 20° C./hNo/scr/evap n/a n/a B

Example 30

TABLE 12 Binary Solvent Crystallizations of Viloxazine HCl Using MEOH asa Primary Solvent and a Fast Cooling Profile Appearance Drug after anti-amt MeOH Anti- Amount Temp. solvent Recovery Yield (mg) (mL) Solvent(mL) (° C.) Cooling addition Precipitation (mg) (%) Form 25.2 0.5 MeCN2.00 60 Fast some ppt* Yes 13.0 51.6 A 24.8 0.5 EtOAc 2.00 60 Fastturbid Yes 19.8 79.8 B 26.1 0.5 acetone 2.00 60/50 Fast turbid* Yes 19.373.9 A 25.5 0.5 MTBE 0.85 60/50 Fast ppt Yes 20.7 81.2 B 24.7 0.5toluene 2.00 60 Fast turbid* Yes 18.2 73.7 B

Example 31

TABLE 13 Binary Solvent Crystallizations of Viloxazine HCl Using MEOH asa Primary Solvent and a Slow Cooling Profile Appearance Drug after anti-amt MeOH Anti- Amount Temp. solvent Recovery Yield (mg) (mL) Solvent(mL) (° C.) Cooling addition Precipitation (mg) (%) Form 25.6 0.5 MeCN6.00 60 20° C./h some ppt* Yes 14.4 56.3 A 24.5 0.5 acetone 2.00 60/5020° C./h turbid Yes 17.9 73.1 A 25.6 0.5 MTBE 0.87 60/50 20° C./h pptYes 19.5 76.2 B 25.2 0.5 THF 3.00 60 20° C./h turbid Yes 19.8 78.6 A24.4 0.5 toluene 2.00 60 20° C./h light turbid Yes 16.6 68.0 B 25.7 0.5heptane 1.00 60 20° C./h 2 layers Yes 16.8 65.4 A

Example 32

TABLE 14 Binary Solvent Crystallizations of Viloxazine HCl Using EtOH asa Primary Solvent and a fast Cooling Profile Appearance Drug after anti-amt EtOH Anti- Amount Temp. solvent Precip- Recovery Yield (mg) (mL)Solvent (mL) (° C.) Cooling addition itation (mg) (%) Form 25.9 1.5 MeCN6.00 75 Fast clear Yes 11.2 43.2 A 25.2 1.5 MTBE 3.00 75/50 Fast turbidYes 20.1 79.8 B 24.7 1.5 toluene 6.00 75 Fast clear Yes 19.1 77.3 B 24.61.5 heptane 5.00 75 Fast turbid Yes 20.2 82.1 B

Example 33

TABLE 15 Binary Solvent Crystallizations of Viloxazine HCl Using EtOH asa Primary Solvent and a Slow Cooling Profile Appearance Drug after anti-amt EtOH Anti- Amount Temp. solvent Precip- Recovery Yield (mg) (mL)Solvent (mL) (° C.) Cooling addition itation (mg) (%) Form 25.5 1.5 MeCN6.00 75 20° C./h clear No/scr/ppt 6.2 24.3 A 25.6 1.5 EtOAc 6.00 75 20°C./h clear Yes 19.3 75.4 A 25.2 1.5 acetone 6.00 75/50 20° C./h clearYes 16.3 64.7 A 25.6 1.5 MTBE 2.55 75/50 20° C./h turbid Yes 21.1 82.4 B26.2 1.5 toluene 6.00 75 20° C./h clear No/scr/ppt 7.7 29.4 B

Example 34

TABLE 16 Binary Solvent Crystallizations of Viloxazine HCl Using AceticAcid as a Primary Solvent and a Fast Cooling Profile Appearance Drugafter anti- amt AcOH Anti- Amount Temp. solvent Precip- Recovery Yield(mg) (mL) Solvent (mL) (° C.) Cooling addition itation (mg) (%) Form25.2 0.3 MeCN 7.00 75 Fast clear Yes 14.6 57.9 A 25.3 0.3 MTBE 1.0075/50 Fast turbid Yes 19.5 77.1 B 25.8 0.3 toluene 7.00 75 Fast clearYes 19.9 77.1 B 24.7 0.3 DCM 7.00 75/40 Fast clear No/scr/evap n/a n/a A

Example 35

TABLE 17 Binary Solvent Crystallizations of Viloxazine HCl Using AceticAcid as a Primary Solvent and a Slow Cooling Profile Appearance Drugafter anti- amt AcOH Anti- Amount Temp. solvent Precip- Recovery Yield(mg) (mL) Solvent (mL) (° C.) Cooling addition itation (mg) (%) Form25.4 0.3 MeCN 7.00 75 20° C./h clear No/scr/ppt 11.3 44.5 A 25.8 0.3EtOAc 2.40 75 20° C./h turbid Yes 18.9 73.3 A 25.5 0.3 acetone 1.7575/50 20° C./h turbid Yes 17 66.7 B 25.6 0.3 MTBE 0.80 75/50 20° C./hturbid Yes 16.6 64.8 B 25 0.3 THF 1.25 75/60 20° C./h turbid Yes 17.871.2 B 25.1 0.3 toluene 7.00 75 20° C./h clear Yes 18.1 72.1 B 25.8 0.3DCM 7.00 75/40 20° C./h clear No/scr/evap n/a n/a A

Example 36

TABLE 18 Binary Solvent Crystallizations of Viloxazine HCl Using DMF asa Primary Solvent and a Fast Cooling Profile Appearance Drug after anti-amt DMF Anti- Amount Temp. solvent Precip- Recovery Yield (mg) (mL)Solvent (mL) (° C.) Cooling addition itation (mg) (%) Form 25.1 1.0 MeCN6.00 75 Fast clear Yes 17.8 70.9 A 26 1.0 MTBE 0.75 75/50 Fast turbidYes 20.1 77.3 B 25.9 1.0 THF 2.00 75/60 Fast turbid Yes 19.7 76.1 A 25.21.0 toluene 3.00 75 Fast turbid Yes 20.1 79.8 B 24.7 1.0 heptane 1.00 75Fast 2 layers Yes 18.6 75.3 A 25.2 1.0 DCM 6.00 75/40 Fast clear Yes 9.236.5 A

Example 37

TABLE 19 Binary Solvent Crystallizations of Viloxazine HCl Using DMF asa Primary Solvent and a Slow Cooling Profile Appearance Drug after anti-amt DMF Anti- Amount Temp. solvent Precip- Recovery Yield (mg) (mL)Solvent (mL) (° C.) Cooling addition itaion (mg) (%) Form 25.9 1.0 MeCN6.00 75 20° C./h clear Yes 15.4 59.5 A 26.1 1.0 EtOAc 1.90 75 20° C./hturbid Yes 20.2 77.4 A 25.8 1.0 MTBE 0.85 75/50 20° C./h turbid Yes 19.374.8 B 26.1 1.0 THF 2.25 75/60 20° C./h turbid Yes 20.2 77.4 A 25.0 1.0toluene 3.00 75 20° C./h turbid Yes 20.7 82.8 B 25.6 1.0 heptane 1.00 7520° C./h 2 layers Yes 18.3 71.5 A 25.0 1.0 DCM 6.00 75/40 20° C./h clearNo/scr/ev/ppt 12.8 51.2 A

Example 38

TABLE 20 Binary Solvent Crystallizations of Viloxazine HCl Using NMP asa Primary Solvent and a Fast Cooling Profile Appearance Drug after anti-amt NMP Anti- Amount Temp. solvent Precip- Recovery Yield (mg) (mL)Solvent (mL) (° C.) Cooling addition itation (mg) (%) Form 25.7 1.0 MeCN6.00 75 Fast clear Yes 14.1 54.9 A 26.2 1.0 EtOAc 2.00 75 Fast TurbidYes 19.6 74.8 A 25.6 1.0 acetone 2.00 75/50 Fast Turbid Yes 19.0 74.2 A25.6 1.0 THF 2.90 75/60 Fast Turbid Yes 19.4 75.8 A 25.8 1.0 toluene3.00 75 Fast Turbid Yes 20.2 78.3 B 25.4 1.0 heptane 1.00 75 Fast 2layers Yes 18.4 72.4 A 25.6 1.0 DCM 6.00 75/40 Fast clear small 1.7 6.6A

Example 39

TABLE 21 Binary Solvent Crystallizations of Viloxazine HCl Using NMP asa Primary Solvent and a Slow Cooling Profile Appearance Drug after anti-amt NMP Anti- Amount Temp. solvent Precip- Recovery Yield (mg) (mL)Solvent (mL) (° C.) Cooling addition itation (mg) (%) Form 25.8 1.0 MeCN6.00 75 20° C./h clear No/scr/ppt 12.1 46.9 A 24.9 1.0 EtOAc 2.00 75 20°C./h Turbid Yes 18.1 72.7 A 25.8 1.0 acetone 2.55 75/50 20° C./h TurbidYes 18.5 71.7 A 24.7 1.0 MTBE 1.30 75/50 20° C./h Turbid Yes 19.3 78.1 B25.7 1.0 THF 2.90 75/60 20° C./h Turbid Yes 19.6 76.3 A 25.7 1.0 toluene3.25 75 20° C./h Turbid Yes 20.4 79.4 B 25.2 1.0 heptane 1.00 75 20°C./h 2 layers Yes 17.6 69.8 A 25.6 1.0 DCM 6.00 75/40 20° C./h clearNo/scr/ev/ppt 12.6 49.2 A

Example 40

TABLE 22 Binary Solvent Crystallizations of Viloxazine HCl Using Wateras a Primary Solvent and a Fast Cooling Profile Appearance Drug afteranti- amt Water Anti- Amount Temp. solvent Precip- Recovery Yield (mg)(mL) Solvent (mL) (° C.) Cooling addition itation (mg) (%) Form 25.5 0.2MeOH 5.00 75/60 Fast Clear No/scr/evap n/a n/a B 25.3 0.2 EtOH 5.00 75Fast Clear No/scr/evap n/a n/a A 25.2 0.2 IPA 5.00 75 Fast ClearNo/scr/ppt 8.6 34.1 A 26 0.2 acetone 5.00 75/50 Fast Clear Yes 18.3 70.4A 24.9 0.2 MeCN 5.00 75 Fast Clear Yes 10.8 43.4 A 25.2 0.2 DMF 5.00 75Fast Clear No/scr/ev/ppt 11.9 47.2 A 25.9 0.2 NMP 5.00 75 Fast ClearNo/scr/evap n/a n/a n/a

Example 41

TABLE 23 Binary Solvent Crystallizations of Viloxazine HCl Using Wateras a Primary Solvent and a Slow Cooling Profile Appearance Drug afteranti- amt Water Anti- Amount Temp. solvent Precip- Recovery Yield (mg)(mL) Solvent (mL) (° C.) Cooling addition itation (mg) (%) Form 26 0.2MeOH 5.00 75/60 20° C./h clear No/scr/evap n/a n/a B 25.0 0.2 IPA 5.0075 20° C./h clear Yes 8.6 34.4 A 25.0 0.2 acetone 5.00 75/50 20° C./hclear Yes 13.3 53.2 A 25.1 0.2 THF 5.00 75/60 20° C./h clear Yes 13.955.4 A 25.2 0.2 dioxane 5.00 75 20° C./h clear Yes 17.4 69.0 A 25.4 0.2MeCN 5.00 75 20° C./h clear No/scr/ppt 8.3 32.7 A 25.9 0.2 DMF 5.00 7520° C./h clear No/scr/ev/ppt 14.1 54.4 A 25.3 0.2 NMP 5.00 75 20° C./hclear No/scr/evap n/a n/a n/a

Example 42

TABLE 24 Scale-Up Experiments of Form A and Form B Appearance Drug afteranti- amt MeOH Anti- Amount Temp. solvent Precip- Recovery Yield Form(mg) (mL) Solvent (mL) (° C.) Cooling addition itation (mg) (%) [XRPD]500 10 acetone 40 60/50 20° C./h Clear Yes 401.5 80.3 A+ 500 10 MTBE 1560/50 Fast Turbid Yes 436.9 87.4 B 500 10 MeCN 60 60 Fast Clear Yes285.5 57.1 A

Example 43

TABLE 25 Stability Evaluation of viloxazine HCl polymorphs. StartingAmount Amount Temp Form in Form in Form (mg) Solvent (mL) (° C.) 7 days14 days A + B 30.6 MeOH 0.5 RT A + B A + B 30.0 EtOH 0.5 RT A + B A + B30.5 IPA 0.5 RT A + B A + B 29.9 THF 0.5 RT A + B A + B 31.3 AcOH 0.5 RTA + B A + B 31.7 DMF 0.5 RT A + B A + B 30.2 NMP 0.5 RT A + B A + B 41.5water 0.5 RT B B A 16.3 MeCN 0.4 RT A A 18.7 MeOH 0.4 RT A A 25.8 water0.4 RT A A B 15.1 MeCN 0.4 RT B B 16.7 MeOH 0.4 RT B B 31.7 water 0.4 RTB B

Example 44

TABLE 26 Stability Evaluation of viloxazine HCl polymorphs. Form A+ FormB Amount Temp. Form in Form in (mg) (mg) Solvent (mL) (° C.) 6 days 12days 14.6 14.7 toluene 0.5 RT A + B* A + B* 14.7 14.6 MeCN 0.5 RT A + B*B+** 14.9 14.6 acetone 0.5 RT A + B* A + B* 14.9 14.7 MeCN/ 0.5 RT B B10% water 15.4 15.5 acetone/ 0.5 RT B B 10% water 16.0 15.6 toluene 0.540 A + B* A + B * 16.4 16.3 MeCN 0.5 40 A + B* B+** 15.7 15.8 acetone0.5 40 A + B* A + B* 20.9 19.9 MeOH 0.5 40 A + B A + B

Example 45

TABLE 27 Gravimetric Solubility of Viloxazine HCl Form A and Form B APISolvent Starting amount amount Temp Solubility Final Form (mg) Solvent(mL) (° C.) (mg/mL) Form Form A 31.5 water 0.3 RT 43.54 A 17.7 methanol0.3 RT 10.90 A Form B 29.4 water 0.3 RT 41.89 B 23.0 methanol 0.3 RT10.73 B

TABLE 28 Thermal Stability Study at 60° C. Starting Form after Formafter Form 8 days 14 days A A A B B B A + B A + B A + B A + B A + B A +B

TABLE 29 Thermal Stress Experiments on Viloxazine HCl Using DSC methodFinal Starting Form Form DSC method [XRPD] A 30-170° C.(10° C./min),hold A 170° C./30 min B 30-170° C.(10° C./min), hold B 170° C./30 minA + B 30-170° C.(10° C./min), hold A + B 170° C./30 min A + B 30-170°C.(10° C./min), hold A + B 170° C./180 min B 30-170° C.(10° C./min),hold B 170° C./180 min A 30-170° C.(10° C./min), hold A 170° C./180 min

TABLE 30 DSC Experiments on Viloxazine HCl with various ramping ratesHeating rate 1° C./min 10° C./min 50° C./min Heat of Heat of Heat ofPeak fusion Peak fusion Peak fusion Form (° C.) (J/g) (° C.) (J/g) (°C.) (J/g) A 187.0 199.3 188.4 204.6 188.6 203.6 B 185.6 202.2 186.5202.0 187.3 205.4 A + B 186.5 196.4 186.9 194.6 189.3 189.4

TABLE 31 Humidity Chamber Study on Viloxazine HCl at 95% RH StartingAmount Form in Form (mg) 7 days A 8.4 A B 7.2 B A + B 14.5 A + B

While this description is made with reference to exemplary embodiments,it will be understood by those skilled in the art that various changesmay be made and equivalents may be substituted for elements thereofwithout departing from the scope. In addition, many modifications may bemade to adapt a particular situation or material to the teachings hereofwithout departing from the essential scope. Also, in the drawings andthe description, there have been disclosed exemplary embodiments and,although specific terms may have been employed, they are unlessotherwise stated used in a generic and descriptive sense only and notfor purposes of limitation, the scope of the claims therefore not beingso limited. Moreover, one skilled in the art will appreciate thatcertain steps of the methods discussed herein may be sequenced inalternative order or steps may be combined. Therefore, it is intendedthat the appended claims not be limited to the particular embodimentdisclosed herein.

1.-32. (canceled)
 33. A substantially pure composition consistingessentially of viloxazine or its pharmaceutically acceptable salt andcomprising genotoxic impurities, per daily viloxazine dose of up to 800mg, less than 1.6 ppm of epichlorohydrin, less than 1.6 ppm of1-(ethoxyphenoxy)-2,3-epoxypropane, less than 1.6 ppm ofpara-toluenesulfonate ethyl ester (EE), less than 1.6 ppm ofpara-toluenesulfonate isopropyl ester (IE), less than 1.6 ppm ofpara-toluenesulfonate 2-aminoethyl ester (AE), less than 1.6 ppm ofpara-toluenesulfonate N-benzyl-2-aminoethyl ester (BE).
 34. Asubstantially pure composition consisting essentially of viloxazine orits pharmaceutically acceptable salt, wherein viloxazine or itspharmaceutically acceptable salt comprises, per daily viloxazine dose ofup to 800 mg, less than 1.6 ppm of epichlorohydrin.
 35. A substantiallypure composition consisting essentially of viloxazine or itspharmaceutically acceptable salt, wherein viloxazine or itspharmaceutically acceptable salt comprises, per daily viloxazine dose ofup to 800 mg, less than 1.6 ppm of 1-(ethoxyphenoxy)-2,3-epoxypropane.36. A substantially pure composition consisting essentially ofviloxazine or its pharmaceutically acceptable salt, wherein viloxazineor its pharmaceutically acceptable salt comprises, per daily viloxazinedose of up to 800 mg, less than 1.6 ppm of para-toluenesulfonate ethylester (EE).
 37. A substantially pure composition consisting essentiallyof viloxazine or its pharmaceutically acceptable salt, whereinviloxazine or its pharmaceutically acceptable salt comprises, per dailyviloxazine dose of up to 800 mg, less than 1.6 ppm ofpara-toluenesulfonate isopropyl ester (IE).
 38. A substantially purecomposition consisting essentially of viloxazine or its pharmaceuticallyacceptable salt, wherein viloxazine or its pharmaceutically acceptablesalt comprises, per daily viloxazine dose of up to 800 mg, less than 1.6ppm of para-toluenesulfonate 2-aminoethyl ester (AE).
 39. Asubstantially pure composition consisting essentially of viloxazine orits pharmaceutically acceptable salt, wherein viloxazine or itspharmaceutically acceptable salt comprises, per daily viloxazine dose ofup to 800 mg, less than 1.6 ppm of para-toluenesulfonateN-benzyl-2-aminoethyl ester (BE).
 40. A substantially pure compositionconsisting essentially of viloxazine or its pharmaceutically acceptablesalt and comprising genotoxic impurities epichlorohydrin,1-(ethoxyphenoxy)-2,3-epoxypropane, para-toluenesulfonate ethyl ester(EE), para-toluenesulfonate isopropyl ester (IE), para-toluenesulfonate2-aminoethyl ester (AE), and para-toluenesulfonate N-benzyl-2-aminoethylester (BE).
 41. A substantially pure composition consisting essentiallyof viloxazine or its pharmaceutically acceptable salt, whereinviloxazine or its pharmaceutically acceptable salt comprises, per dailyviloxazine dose of up to 800 mg, less than 2.1 ppm of the total of thefour p-toluene sulfonate impurities (para-toluenesulfonate ethyl ester(EE), para-toluenesulfonate isopropyl ester (IE), para-toluenesulfonate2-aminoethyl ester (AE), and para-toluenesulfonate N-benzyl-2-aminoethylester (BE)).
 42. A substantially pure composition consisting essentiallyof viloxazine or its pharmaceutically acceptable salt and comprisingless than 5 micrograms of genotoxic impurities per daily viloxazine doseof up to 800 mg.
 43. A substantially pure composition consistingessentially of viloxazine or its pharmaceutically acceptable salt andcomprising: a) the genotoxic impurity epichlorohydrin having the formula

b) the genotoxic impurity 1-(ethoxyphenoxy)-2,3-epoxypropane having theformula

c) the genotoxic impurity para-toluenesulfonate ethyl ester (EE) havingthe formula

d) the genotoxic impurity para-toluenesulfonate isopropyl ester (IE)having the formula

e) the genotoxic impurity para-toluenesulfonate 2-aminoethyl ester (AE)having the formula

and f) the genotoxic impurity para-toluenesulfonateN-benzyl-2-aminoethyl ester (BE) having the formula